CN111132568A

CN111132568A - Aerosol delivery device comprising a substrate having improved absorption characteristics

Info

Publication number: CN111132568A
Application number: CN201880035167.8A
Authority: CN
Inventors: A·D·赛巴斯蒂安; M·F·戴维斯; P·D·菲利普斯
Original assignee: RAI Strategic Holdings Inc
Current assignee: RAI Strategic Holdings Inc
Priority date: 2017-03-29
Filing date: 2018-03-28
Publication date: 2020-05-08
Anticipated expiration: 2038-03-28
Also published as: CN111132568B; PH12019502226A1; EP3599914B1; EP3599914A1; WO2018178900A1; CA3058142A1; JP2020521434A; ZA201906538B; AU2018242603B2; KR20190127947A; KR102626730B1; UA126476C2; CL2019002751A1; JP7050086B2; RU2019131036A3; US10440995B2; MX2019011671A; AR111311A1; RU2019131036A; AU2018242603A1

Abstract

The present disclosure relates to aerosol delivery devices (100), methods of forming the devices, and elements of the devices. In some embodiments, the present disclosure provides a substrate for storing a pre-aerosol body fluid and/or delivering the liquid to a heater (134,230,330,430,830) for evaporation. The substrate may be formed from fibers (500) capable of providing improved absorbency and/or transport qualities. Also disclosed is a multi-layer substrate (700) that may include a highly absorbent layer (760) and a hydrophobic layer (770).

Description

Aerosol delivery device comprising a substrate having improved absorption characteristics

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices such as smoking articles, and more particularly to aerosol delivery devices that can utilize heat generated by electricity to produce an aerosol (e.g., smoking articles commonly referred to as electronic cigarettes). The smoking article may be configured to heat an aerosol precursor, which may comprise a material that may be prepared or derived from tobacco, or may comprise tobacco, the precursor being capable of forming an inhalable substance for human consumption.

Background

Many smoking devices have been proposed over the years as an improvement or alternative to smoking products that require the combustion of tobacco for use. Many of these devices are purportedly designed to provide a sensation associated with a cigarette, cigar or pipe without delivering significant quantities of incomplete combustion products and pyrolysis products resulting from the combustion of tobacco. For this reason, many smoking products, flavor generators, and medicine inhalers that use electric energy to evaporate or heat volatile materials, or many smoking products, flavor generators, and medicine inhalers that attempt to provide the sensation of a cigarette, cigar, or pipe without burning tobacco to a large extent have been proposed. See, for example, various smoking articles, aerosol delivery devices, and heat generation sources described in the background art as described in U.S. patent No. 7,726,320 to Robinson et al, U.S. patent publication No. 2013/0255702 to Griffith jr. et al, and U.S. patent publication No. 2014/0096781 to Sears et al, which are incorporated herein by reference. See also, for example, various types of smoking articles, aerosol delivery devices, and electrically-driven heat generation sources, referenced by trade names and commercial sources in U.S. patent publication No. 2015/0216232 to Bless et al, which is incorporated herein by reference in its entirety.

It would be desirable to provide a reservoir for an aerosol precursor composition for use in an aerosol delivery device, which reservoir is provided to improve the construction of the aerosol delivery device. It would also be desirable to provide an aerosol delivery device prepared using such a reservoir.

BRIEF SUMMARY OF THE PRESENT DISCLOSURE

The present disclosure relates to aerosol delivery devices, methods of forming the devices, and elements of the devices. The aerosol delivery device can provide improved storage and/or delivery of the aerosol precursor composition. In particular, the substrates described herein can be formed from fibers such that the substrates exhibit a surprising increase in the storage capacity of the aerosol precursor composition.

In one or more embodiments, the aerosol delivery devices described herein can comprise: a housing; a substrate formed at least in part from regenerated cellulose fibers; an aerosol-forming liquid held by the substrate; and a heater operatively arranged to vaporise the aerosol-forming liquid. Preferably, the regenerated cellulose fibers comprise one or more of the following fibers: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive. In other embodiments, the aerosol delivery device may be further defined by one or more of the following expressions, which expressions may be combined in any number and order.

The regenerated cellulose fibers may have a multi-lobal cross-section and include striations extending longitudinally along the surface of one or more lobes of the fibers.

The substrate may be a nonwoven.

The substrate may comprise a plurality of layers.

One layer of the substrate and/or a combination of layers forming the substrate may be needled.

The combination of the layers forming the substrate may be bonded together.

The substrate may include a first layer comprising one or both of regenerated cellulose fibers having a hollow, substantially cylindrical cross-section and regenerated cellulose fibers having a multi-lobal cross-section, and a second layer comprising regenerated cellulose fibers comprising a hydrophobic additive.

The first layer of the substrate may be configured to store and release the aerosol precursor composition, and the second layer of the substrate may be hydrophobic.

The substrate may form at least a portion of the reservoir.

The aerosol delivery device may further comprise a liquid transport element in fluid communication with the reservoir and in fluid communication with the heater.

The substrate may form at least a portion of a liquid transport element in fluid communication with the reservoir and in fluid communication with the heater.

The substrate may be in direct contact with the heater.

The aerosol precursor composition carrying capacity of the substrate may be at least 2000% relative to the initial dry weight of the substrate.

The substrate may have a basis weight of from about 100gsm (grams per square meter) to about 250 gsm.

The aerosol delivery device may further comprise a power source and a controller.

In one or more embodiments, the present invention can also provide a method of making an aerosol delivery device. For example, the method may comprise: providing a housing; disposing a substrate within the housing, at least a portion of the substrate being formed from regenerated cellulose fibers comprising one or more of the following: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive; and disposing the substrate in fluid communication with a heater within the housing; wherein an aerosol-forming liquid is retained by the substrate before or after the substrate is placed within the housing. In other embodiments, the method may be defined by one or more of the following expressions.

The method may further include combining the housing with a cuff (mouthpiece).

The method may further include combining the housing with a second housing including a battery and a controller.

The present invention includes, but is not limited to, the following embodiments:

embodiment 1: an aerosol delivery device comprising: a housing; a substrate formed at least in part from regenerated cellulose fibers; an aerosol-forming liquid held by the substrate; and a heater operatively arranged to vaporise the aerosol-forming liquid; wherein the regenerated cellulose fibers comprise one or more of the following fibers: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive.

Embodiment 2: the aerosol delivery device of any preceding embodiment, wherein the regenerated cellulose fibers have a multi-lobal cross-section and comprise stripes extending longitudinally along the surface of one or more lobes of the fibers.

Embodiment 3: the aerosol delivery device of any preceding embodiment, wherein the substrate is a nonwoven.

Embodiment 4: the aerosol delivery device of any preceding embodiment, wherein the substrate comprises a plurality of layers.

Embodiment 5: the aerosol delivery device of any preceding embodiment, wherein the plurality of layers are needle punched.

Embodiment 6: the aerosol delivery device of any preceding embodiment, wherein the plurality of layers are bonded together.

Embodiment 7: the aerosol delivery device of any preceding embodiment, wherein the substrate comprises a first layer comprising one or both of regenerated cellulose fibers having a hollow, substantially cylindrical cross-section and regenerated cellulose fibers having a multi-lobal cross-section, and a second layer comprising regenerated cellulose fibers comprising a hydrophobic additive.

Embodiment 8: the aerosol delivery device of any preceding embodiment, wherein the first layer is configured to store and release the aerosol precursor composition and the second layer is hydrophobic.

Embodiment 9: the aerosol delivery device of any preceding embodiment, wherein the substrate forms at least a portion of a reservoir.

Embodiment 10: the aerosol delivery device of any preceding embodiment, further comprising a liquid transport element in fluid communication with the reservoir and in fluid communication with the heater.

Embodiment 11: the aerosol delivery device of any preceding embodiment, wherein the substrate forms at least a portion of a liquid transport element, the liquid transport element being in fluid communication with the reservoir and in fluid communication with the heater.

Embodiment 12: the aerosol delivery device of any preceding embodiment, wherein the substrate is in direct contact with a heater.

Embodiment 13: the aerosol delivery device of any preceding embodiment, wherein the substrate has an aerosol precursor composition carrying capacity of at least 2000% relative to the initial dry weight of the substrate.

Embodiment 14: the aerosol delivery device of any preceding embodiment, wherein the substrate has a basis weight of about 100gsm to about 250 gsm.

Embodiment 15: the aerosol delivery device of any preceding embodiment, wherein the aerosol delivery device further comprises a power source and a controller.

Embodiment 16: a method of making an aerosol delivery device, the method comprising: providing a housing; disposing a substrate within the housing, at least a portion of the substrate being formed from regenerated cellulose fibers comprising one or more of the following: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive; and disposing the substrate in fluid communication with a heater within the housing; wherein an aerosol-forming liquid is retained by the substrate before or after the substrate is placed within the housing.

Embodiment 17: the method of any of the preceding embodiments, further comprising combining the shell with a cuff.

Embodiment 18: the method of any of the preceding embodiments, further comprising combining the housing with a second housing comprising a battery and a controller.

These and other features, aspects, and advantages of the present invention will become apparent from the following detailed description, which is to be read in connection with the accompanying drawings, which are briefly described below. The present invention includes combinations of two, three, four or more of the above-described embodiments, and combinations of two, three, four or more of the features or elements set forth herein, whether or not such features or elements are expressly combined in a particular embodiment described herein. Any divisible feature or element of the disclosed methods in any of its various aspects and embodiments should be considered as being intended to be combinable features or elements unless the context clearly dictates otherwise.

Drawings

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

fig. 1 is a partial cross-sectional view of an aerosol delivery device including a cartridge and a control body including various elements that may be used in an aerosol delivery device according to various embodiments of the present invention;

FIG. 2 is a diagram of a substrate in combination with a separate reservoir and heater, the substrate thus functioning as a liquid transport element, according to an embodiment of the invention;

FIG. 3 is a partial cross-sectional view of a substrate in combination with a separate reservoir and heater, the substrate thus functioning as a liquid transport element, according to an embodiment of the present invention;

FIG. 4 is a diagram of a substrate that functions as an intermediate liquid transport element by combining with a reservoir and a separate wick and heater, according to an embodiment of the invention;

FIG. 5A is a cross-sectional view of a multilobal fiber, specifically a trilobal fiber, according to an embodiment of the present invention;

FIG. 5B is a cross-sectional view of a multi-lobal fiber having four lobes in accordance with an embodiment of the present invention;

FIG. 5C is a cross-sectional view of a multi-lobal fiber having seven lobes in accordance with embodiments of the present invention;

FIG. 5D is a diagram of a trilobal fiber according to an embodiment of the invention, each blade comprising a face (or surface) having striations disposed longitudinally thereon;

FIG. 6 is a diagram of a hollow fiber according to an embodiment of the present invention;

FIG. 7 is a diagram of a substrate formed from multiple layers and configured for movement of liquid therefrom substantially only from one side (or surface) of the substrate, according to the present invention;

FIG. 8 is a partial cross-sectional view of a cartridge according to an embodiment of the invention, including a multi-layer substrate;

FIG. 9 is a graph showing percent load bearing capacity of various substrates according to the present invention relative to 1 control sample and 2 comparative samples;

FIG. 10 is a graph showing the relative load gain of a substrate according to the present invention compared to 1 control sample;

figure 11 is a graph showing total particulate matter per puff in an aerosol delivery device having a reservoir formed from a substrate according to the present invention; and

figure 12 is a graph showing total particulate matter per puff in an aerosol delivery device having a reservoir formed from a substrate according to the present invention.

Detailed Description

The present invention will be described in more detail below with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

As described herein, embodiments of the present invention are directed to aerosol delivery systems. The aerosol delivery system according to the present invention uses electrical energy to heat the material (preferably without burning the material to any significant extent and/or without significant chemical alteration of the material) to form an inhalable substance; and the components of the system are in the form of an article that is most preferably compact enough to be considered a hand-held device. That is, the use of the components of the preferred aerosol delivery systems does not result in the production of smoke, a by-product from the combustion or pyrolysis of tobacco, rather, the use of these preferred systems results in the production of steam resulting from the volatilization or evaporation of certain components contained therein. In preferred embodiments, the components of the aerosol delivery system may be characterized as e-cigarettes, which most preferably comprise tobacco and/or components derived from tobacco, and thus deliver the tobacco-derived components in aerosol form.

The aerosol-generating segment of the preferred aerosol delivery system can provide many of the sensations (such as inhalation and exhalation rituals, types of tastes or flavors, sensory effects, physical sensations, usage rituals, visual signals provided by, for example, visible aerosols, etc.) of smoking a cigarette, cigar, or pipe (and thus inhaling tobacco smoke) by igniting and burning tobacco without any substantial degree of combustion of any of its components. For example, a user of the aerosol generating segment of the present invention may hold and use the segment like a smoker using a conventional smoking article, draw on one end thereof to inhale an aerosol generated by the segment, draw or puff at selected intervals, and the like.

The aerosol delivery device of the present invention may also be characterized as a vapor-generating article or a drug delivery article. Thus, the article or device may be adapted to provide one or more substances (e.g. a fragrance and/or a pharmaceutically active ingredient) in an inhalable form or state. For example, the inhalable substance may be substantially in vapour form (i.e. a substance that is in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e. a suspension of fine solid particles or liquid droplets in a gas). For the sake of brevity, the term "aerosol" as used herein is intended to include vapors, gases and aerosols in a form or kind suitable for human inhalation, whether visible or not, and whether in a form that can be considered as a smoke.

The aerosol delivery device of the present invention typically comprises a plurality of components provided in one outer body or housing (which may be referred to as a shell). The overall design of the outer body or housing may vary, and the format or configuration of the outer body, which can define the overall size and shape of the aerosol delivery device, may vary. In general, the elongated body may be formed from a single overall housing, resembling the shape of a cigarette or cigar, or the elongated housing may be formed from two or more divisible bodies. For example, the aerosol delivery device may comprise an elongate housing or body which may be substantially tubular in shape and thus resemble a common cigarette or cigar shape. In one embodiment, all components of the aerosol delivery device are contained within one housing. Alternatively, the aerosol delivery device may comprise two or more housings that are connected and separable. For example, the aerosol delivery device may have a control body at one end comprising an outer shell containing one or more components (such as a battery and various electronics for controlling the operation of the article) and a removably attached outer body or housing at the other end comprising aerosol-forming components (such as one or more aerosol precursor components, e.g. a perfume and an aerosol former, one or more heaters and/or one or more wicks).

The aerosol delivery device of the present invention may be formed from an outer shell or housing which is not substantially tubular in shape but may be formed to substantially larger dimensions. The housing or case may be configured to include a mouthpiece and/or may be configured to receive a separate case (e.g., a cartridge or can) that may include a consumable element, such as a liquid aerosol-forming substance, and may include a vaporizer or an atomizer.

The aerosol delivery device of the present invention most preferably comprises some combination of the following components: a power source (i.e., a source of electrical power), at least one control component (such as a device, e.g., a microcontroller or microprocessor, for activating, controlling, regulating, and stopping a source of heat-generating energy, e.g., by controlling the flow of electrical current from the power source to other components of the article), a heater or heat-generating means (such as a resistive heating element or other component, which may be generally referred to as an "atomizer" alone or in combination with one or more other components), aerosol precursor compositions (e.g., liquids that are generally capable of generating an aerosol by the application of sufficient heat, such as the components commonly referred to as "tobacco," e-liquid, "and" e-liquid "), and a mouthpiece or mouthpiece region that allows the aerosol delivery device to be drawn for inhalation of the aerosol (e.g., through a well-defined airflow path of the article, thereby allowing the generated aerosol to be drawn therefrom by smoking).

More specific formats, configurations and arrangements of components in the aerosol delivery system of the present invention will become apparent from the further description provided below. Additionally, it will be appreciated that the selection and arrangement of the various aerosol delivery system components is to take into account commercially available electronic aerosol delivery devices, such as those representative products referenced in the background section of the invention.

Fig. 1 provides an exemplary embodiment of an aerosol delivery device 100 showing components that may be used in an aerosol delivery device according to the present invention. As can be seen from the cross-sectional views shown therein, the aerosol delivery device 100 can include a control body 102 and a cartridge 104, which can be permanently or removably arranged in a functional relationship. The engagement of the control body 102 and the cartridge 104 may be a press fit (as shown), threads, an interference fit, magnetic forces, or the like. In particular, connecting members such as those described further herein may be used. For example, the control body may include a coupler adapted to engage a connector on the cartridge.

In particular embodiments, one or both of control body 102 and cartridge 104 may be disposable or reusable. For example, the control body may have a replaceable or rechargeable battery and may therefore be combined with any kind of charging technique, including connection to a typical electrical outlet, connection to an on-board charger (i.e. cigarette lighter socket), and connection to a computer (e.g. via a Universal Serial Bus (USB) data line). For example, an adapter including a USB connector at one end and a control body connector at the opposite end is described in U.S. patent publication No. 2014/0261495 to Novak et al, which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the cartridge may comprise a single use cartridge, which is described in U.S. patent No. 8,910,639 to Chang et al, which is incorporated herein by reference in its entirety.

As shown in fig. 1, the control body 102 may be formed of a control body housing 101, a flow sensor 108, a battery 110, and an LED112, the control body housing 101 may include control components 106 (e.g., a Printed Circuit Board (PCB), an integrated circuit, memory components, a microcontroller, etc.), which may be arranged in various ways. Other indicators (e.g., tactile feedback, audible feedback, etc.) may also be included in addition to or in place of the LEDs. Other representative classes of visual signaling components or indicators such as Light Emitting Diode (LED) components, and their configuration and use are described in U.S. patent No. 5,154,192 to springel et al, U.S. patent No. 8,499,766 to Newton, and U.S. patent No. 8,539,959 to Scatterday; galloway et al, U.S. patent publication No. 2015/0020825; and U.S. patent publication No. 2015/0216233 to Sears et al; these documents are incorporated herein by reference.

The cartridge 104 can be formed of a cartridge housing 103 enclosing a reservoir 144, the reservoir housing 144 being in fluid communication with a liquid delivery element 136, the liquid delivery element 136 being adapted to wick or otherwise deliver the aerosol precursor composition stored in the reservoir housing to the heater 134. The liquid transport element may be configured asOne or more materials for transporting a liquid by, for example, capillary action. The liquid transport element may be formed, for example, from fibrous materials (e.g., organic cotton, cellulose acetate, regenerated cellulose fabric, glass fibers), porous ceramics, porous carbon, graphite, porous glass, sintered glass beads, sintered ceramic beads, capillaries, and the like. Thus, the liquid transport element may be any material containing an open pore network (i.e., a plurality of pores in communication with one another such that liquid may flow in multiple directions through the element from one pore to another pore). The resistive heating element 134 may be formed from various embodiments of materials configured to generate heat when an electrical current is applied thereto. Exemplary materials from which the coil may be formed include Corterra (Kanthal) (FeCrAl), Nichrome (Nichrome), molybdenum disilicide (MoSi)₂) Molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (Mo (Si, Al)₂) Titanium, platinum, silver, palladium, graphite and graphite-based materials (such as carbon-based foams and yarns) and ceramics (such as positive temperature coefficient ceramics or negative temperature coefficient ceramics).

Opening 128 may be present in cartridge housing 103 (e.g., at the mouth end) to allow formed aerosol to be expelled from cartridge 104. These components are representative of components that may be present in the cartridge and are not intended to limit the scope of the cartridge components encompassed by the present invention.

The cartridge 104 may also include one or more electronic components 150, which one or more electronic components 150 may include integrated circuits, memory components, sensors, and the like. The electronic component 150 may be adapted to connect with the control component 106 and/or an external device via wired or wireless means. The electronic components 150 may be located anywhere within the cartridge 104 or its base 140.

While the control component 106 and the flow sensor 108 are shown separately, it is understood that the control component and the flow sensor may be combined into one electronic circuit board with the airflow sensor directly connected thereto. In addition, the electronic circuit board may be horizontally placed with respect to fig. 1, wherein the electronic circuit board may be parallel to the central axis of the control body in the length direction. In some embodiments, the airflow sensor may include its own circuit board or other base element to which it may be connected. In some embodiments, a flexible circuit board may be employed. The flexible circuit board may be configured in various shapes, including a substantially tubular shape.

The control body 102 and the cartridge 104 can include components adapted to facilitate the merging of liquids therebetween. As shown in fig. 1, the control body 102 may include a coupler 124 having a cavity 125 therein. The cartridge 104 can include a base 140 adapted to engage the coupler 124 and can include a protrusion 141 adapted to fit within the cavity 125. Such engagement may facilitate a stable connection between the control body 102 and the cartridge 104, and may establish an electrical connection between the battery 110 and the control component 106 in the control body and the heater 134 in the cartridge. Further, the control body housing 101 may include an air inlet 118, which may be a notch in the housing, that interfaces with the coupler 124, allowing ambient air to circulate around and into the housing, then flow through the cavity 125 of the coupler and into the cartridge through the protrusion 141.

Useful couplers and substrates according to the present invention are described in U.S. patent publication No. 2014/0261495 to Novak et al, the disclosure of which is incorporated herein by reference in its entirety. For example, the coupler seen in fig. 1 may define an outer periphery 126, the outer periphery 126 configured to mate with an inner periphery 142 of the base 140. In one embodiment, the inner periphery of the base may define a diameter substantially equal to or slightly larger than the diameter of the outer periphery of the coupler. Additionally, the coupler 124 may define one or more protrusions 129 on the outer periphery 126, the protrusions 129 configured to engage one or more recesses 178 defined on the inner periphery of the base. However, the structures, shapes, and components of various other embodiments may be employed to couple the base with the coupler. In some embodiments, the connection between the base 140 of the cartridge 104 and the coupler 124 of the control body 102 may be substantially permanent, while in other embodiments the connection therebetween may be releasable, such that, for example, the control body may be reusable with one or more other cartridges, which may be disposable and/or refillable.

In some embodiments, the aerosol delivery device 100 may be substantially rod-shaped or substantially tubular-shaped or substantially cylindrical-shaped. In other embodiments, other shapes and dimensions are also contemplated-e.g., rectangular or triangular cross-sections, multi-faceted shapes, and the like. In particular, the control body 102 may be non-rod-shaped and may even be substantially rectangular, circular, or have some other shape. Likewise, the control body 102 may be substantially larger than a control body intended to be substantially of a regular cigarette size.

The reservoir 144 shown in fig. 1 can be a container (e.g., formed by a wall substantially impermeable to the aerosol precursor composition) or can be a fiber reservoir. For example, in the present embodiment, the reservoir 144 can include one or more layers of nonwoven fibers formed substantially into a tubular shape that surrounds the interior of the cartridge housing 103. The aerosol precursor composition may be held in the reservoir 144. The liquid component may be, for example, adsorbably retained by the reservoir 144. The reservoir 144 may be in fluid communication with the liquid transport element 136. In this embodiment, the liquid delivery element 136 can deliver the aerosol precursor composition stored in the reservoir 144 to the heating element 134 in the form of a metal coil by capillary action. As such, heating element 134 is configured to heat liquid delivery element 136.

When the user draws on the article 100, the sensor 108 detects the airflow, the heating element 134 is activated, and the components of the aerosol precursor composition are vaporized by the heating element 134. Suction at the mouth end of the article 100 causes ambient air to enter the air inlet 118 and flow through the cavity 125 in the coupler 124 and the central opening in the protrusion 141 of the base 140. In the cartridge 104, the drawn air combines with the formed vapor to form an aerosol. The aerosol is blown, drawn, or drawn off the heating element 134 and out of the mouthpiece opening 128 in the mouthpiece end of the article 100.

The aerosol delivery device may comprise an input element. The input may be included to allow a user to control the function of the device and/or to output information for the user. Any component or combination of components may be employed as an input for controlling a function of the device. For example, one or more buttons described in U.S. publication No. 2015/0245658 of Worm et al, which is incorporated herein by reference, may be used. Likewise, the touch screen described in U.S. patent publication No. 2016/0262454 to Sears et al, which is incorporated herein by reference, may be used. As another example, a component suitable for gesture recognition based on a particular motion of the aerosol delivery device may be used as an input. See U.S. publication No. 2016/0158782 to Henry et al, which is incorporated herein by reference.

In some implementations, the input may include a computer or computing device, such as a smartphone or tablet. In particular, the aerosol delivery device may be connected to a computer or other device by a wire, for example by using a USB cord or similar protocol. The aerosol delivery device may also be connected to a computer or other device as an input through a wireless connection. See, for example, U.S. publication No. 2016/0007561 to Ampolini et al, the disclosure of which is incorporated herein by reference, for a system and method for controlling a device through a read request. In such embodiments, the APP or other computer program may be used to interface with a computer or other computing device to input control instructions to the aerosol delivery device, including the ability to form an aerosol of a particular composition, for example, by selecting the nicotine level and/or the level of other flavors to be included.

The various components of the aerosol delivery device according to the present invention may be selected from components described and commercially available in the art. An example of a battery useful in accordance with the present invention is described in U.S. patent publication No. 2010/0028766 to Peckerar et al, the disclosure of which is incorporated herein by reference in its entirety.

The aerosol delivery device may comprise a sensor or detector for controlling the supply of power to the heat generating element when aerosol generation is desired (e.g. by drawing during use). As such, for example, a means or method can be provided for turning off power to the heat generating element when the aerosol delivery device is not being drawn during use, and turning on power during drawing to activate or trigger heat generation by the heat generating element. Other representative classes of sensing or detecting mechanisms and their structures and configurations, their components, their conventional methods of operation are described in U.S. patent No. 5,261,424 to springel, jr; McCafferty et al, U.S. Pat. No. 5,372,148; and Flick, PCT WO 2010/003480; these documents are incorporated herein by reference.

The aerosol delivery device most preferably comprises a control mechanism for controlling the amount of power supplied to the heat generating element during smoking. Representative varieties of electronic components, their structures and configurations, their features, and their conventional methods of operation are described in U.S. Pat. nos. 4,735,217 to Gerth et al; U.S. patent No. 4,947,874 to Brooks et al; McCafferty et al, U.S. Pat. No. 5,372,148; U.S. patent No. 6,040,560 to fleischeuer et al; nguyen et al, U.S. Pat. No. 7,040,314 and Pan, U.S. Pat. No. 8,205,622; U.S. patent publication No. 2009/0230117 to Fernando et al; U.S. patent publication Nos. 2014/0060554 to Collet et al and 2014/0270727 to Ampolini et al; and Henry et al, U.S. publication No. 2015/0257445; these documents are incorporated herein by reference.

Representative classes of substrates, reservoirs, or other components for supporting aerosol precursors are described in Newton, U.S. patent No. 8,528,569; U.S. patent publication Nos. 2014/0261487 to Chapman et al and 2014/0059780 to Davis et al; and U.S. publication No. 2015/0216232 to Bless et al; these documents are incorporated herein by reference. In addition, various wicking materials and the configuration and operation of these wicking materials in certain types of electronic cigarettes are described in U.S. patent No. 8,910,640 to Sears et al; this document is incorporated herein by reference.

For aerosol delivery systems characterized as electronic cigarettes, the aerosol precursor composition most preferably comprises tobacco or a component derived from tobacco. In some aspects, the tobacco may be provided in the form of portions or fragments of tobacco, such as finely ground, milled, or powdered tobacco lamina. In another aspect, the tobacco can be provided in the form of an extract, such as a spray-dried extract that includes many of the water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of a relatively high nicotine content extract that also contains minor amounts of other extracted components derived from tobacco. In another aspect, the tobacco-derived component may be provided in a relatively pure form, such as in the form of certain flavorants derived from tobacco. In one aspect, the component derived from tobacco and which can be used in high purity or substantially pure form is nicotine (e.g., pharmaceutical grade nicotine).

The aerosol precursor composition, also referred to as a vapor precursor composition, can comprise various components including, for example, a polyol (such as glycerol, propylene glycol, or mixtures thereof), nicotine, tobacco extract, and/or flavorants. Representative classes of aerosol precursor compositions and formulations are also described and characterized in U.S. patent No. 7,217,320 to Robinson et al and U.S. patent publication No. 2013/0008457 to Zheng et al; U.S. patent publication No. 2013/0213417 to Chong et al; collett et al, U.S. patent publication No. 2014/0060554; lipowicz et al, U.S. patent publication No. 2015/0020823 and Koller, U.S. patent publication No. 2015/0020830; and WO 2014/182736 to Bowen et al; the disclosures of these documents are incorporated herein by reference. Precursor aerosol precursors that can be used include those that have been incorporated into r.j. reynolds smoke Company (r.j. reynolds Vapor Company)

Product, BLU from Lorillard Technologies^TMProducts, aerosol precursors of MISTIC MEDIHOL products from Mistic Ecigs and VYPE products from CN Creative Ltd. Also desirable is the so-called "smoke juice" of an electronic cigarette available from Johnson Creek Enterprises, LLC.

The amount of aerosol precursor incorporated into the aerosol delivery system is such that the aerosol generating segment provides an acceptable feel and desired performance characteristics. For example, it is highly preferred to employ sufficient amounts of aerosol-forming materials (such as glycerin and/or propylene glycol) so as to produce a visible mainstream aerosol that looks like tobacco smoke in many respects. The amount of aerosol precursor within the aerosol-generating system may depend on factors such as the number of puffs desired for each aerosol-generating segment. Generally, the amount of aerosol precursor incorporated into the aerosol delivery system, and in particular into the aerosol generating segment, is less than about 2g, typically less than about 1.5g, often less than about 1g, and often less than about 0.5 g.

Other features, controls or components that may be incorporated into the aerosol delivery system of the present invention are described in Harris et al, U.S. patent No. 5,967,148; U.S. patent No. 5,934,289 to Watkins et al; U.S. patent No. 5,954,979 to Counts et al; U.S. patent No. 6,040,560 to fleischeuer et al; U.S. patent No. 8,365,742 to Hon; U.S. patent No. 8,402,976 to Fernando et al; U.S. patent publication No. 2010/0163063 to Fernando et al; U.S. patent publication No. 2013/0192623 to Tucker et al; U.S. patent publication No. 2013/0298905 to Leven et al; U.S. patent publication No. 2013/0180553 to Kim et al; U.S. patent publication No. 2014/0000638 to Sebastian et al; U.S. patent publication Nos. 2014/0261495 to Novak et al and 2014/0261408 to DePiano et al; these documents are incorporated herein by reference.

The use of the articles described above can be applied to the various embodiments described herein with minor modifications, as will be apparent to those skilled in the art from the further disclosure provided herein. However, the above description of use is not intended to limit the use of the article, but is provided in order to comply with all the necessary requirements of the present disclosure. Any of the elements shown in figure 1 or in the articles described above may be included in an aerosol delivery device according to the present invention.

In one or more embodiments, the present invention may be particularly directed to fibrous substrates configured for use in aerosol delivery devices. The substrate may be formed from a particular type of fiber or fibers that impart desired characteristics with respect to one or both of absorbency and wicking ability. The substrate may be configured for or used as a reservoir. For example, the substrate according to the present invention may be substantially in the form of a non-woven mat that may be substantially formed into a tube shape that surrounds the interior of the housing of the aerosol delivery device. As another example, the substrates described herein may be provided in a separate reservoir container. Suitable reservoir containers are described, for example, in U.S. publication No. 2015/0144145 to Chang et al, the disclosure of which is incorporated herein by reference. Likewise, the substrate can also be configured to function as a liquid transport element. For example, a substrate according to the present invention can have at least two separate ends, portions or surfaces, one of which is in fluid communication with the aerosol precursor composition within the reservoir and the other of which is disposed to be directly heated by the heater (e.g., in direct contact with, for example, a heating coil, or in a radiant heating relationship with radiant heat).

The following embodiments are, by way of non-limiting example, encompassed by the present invention. Referring to fig. 2, the substrate 210 described herein may be in the form of an elongated wick having a first end 211 and a second end 212, the first end 211 being in fluid communication with the aerosol precursor composition 218 within a reservoir 220 (in the form of a bottle), the second end 212 being configured to be heated by a heater 230. Referring to fig. 3, the substrate 310 described herein can be in the form of an elongated core having a first end 311, a second end 312, one or both of which are in fluid communication with the aerosol precursor composition within a reservoir 320 (in the form of a fiber mat in the shape of a tube as shown in cross-section), and an intermediate portion 313, the intermediate portion 313 being configured to be heated by a heater 330. Referring to fig. 4, the substrate 410 described herein may be in the form of a fibrous disk or other cross-sectional shape, thereby being substantially a mat having a first surface 411 in fluid communication with the aerosol precursor composition 418 within the reservoir 420 and an opposing second surface 412 disposed to be heated by the heater 430 or in fluid communication with the wick 440, the wick 418 being configured to deliver the aerosol precursor composition from the substrate to the heater. In other embodiments, a substrate is used as the fiber reservoir. See, for example, fig. 8.

In one or more embodiments, substrates according to the present invention may be formed from fibers made from a variety of materials. For example, suitable fibers may include cellulose acetate, polyethylene terephthalate, cotton, and other natural, man-made, or synthetic materials suitable for forming fibers capable of being formed into a nonwoven substrate. Preferably, at least a portion of the fibers forming the substrate of the present invention are made of regenerated cellulose. By way of non-limiting example, suitable regenerated cellulose can be viscose fibers prepared from a variety of cellulose-containing materials, such as wood (e.g., eucalyptus), grasses (e.g., bamboo), cotton, and other plant-based materials.

In addition to the type of material used to form the fibers, the substrates described herein may exhibit desirable characteristics, which are attributed, at least in part, to the physical structure of the fibers. Fibers, especially extruded fibers, are generally solid and have a substantially circular cross-section. Although fibers of this structure may also be included in the substrate of the present invention (e.g., as a blend), it is particularly useful for the substrate to include fibers having a multi-lobal cross-section. For example, the substrate of the present invention can comprise multilobal fibers in an amount greater than or equal to about 25 weight percent, greater than or equal to about 50 weight percent, greater than or equal to about 60 weight percent, greater than or equal to about 75 weight percent, greater than or equal to about 90 weight percent, or greater than or equal to about 99 weight percent based on the total weight of the fibers present in the substrate. It will be appreciated that the above values should have an inherent maximum of 100% by weight, i.e. in this case all the fibres used to form the substrate are multilobal fibres. In some embodiments, the multilobal fibers may be present in an amount of about 25 to about 100 weight percent, about 50 to about 100 weight percent, or about 90 to about 100 weight percent of the substrate, based on the total weight of the fibers present in the substrate. It should be understood that the terms "multilobal fibers" and "fibers having a multilobal cross-section" are used interchangeably. In some embodiments, a multilobal fiber may be a fiber that includes a conventional matrix or hinge in cross-section (generally at about the center of the fiber cross-section) and at least three lobes or webs extending therefrom. Multilobal fibers may also be defined as fibers having three or more extensions such that at least one set of adjacent extensions forms an angle of less than 180 degrees, thereby defining one or more channels extending longitudinally along the fiber. Non-limiting examples of multilobal fibers are shown in fig. 5A-5D.

As shown in FIG. 5A, a multilobal fiber 500 includes a plurality of lobes 505 extending from a central hub 510, adjacent lobes having an angle α of less than 180 degrees to form channels 515 between adjacent lobes the lobes of the multilobal fiber may have various shapes, as shown in FIG. 5B, the multilobal fiber 500 includes a plurality of substantially circular lobes 505 while they still form a plurality of channels 515 between adjacent lobes As yet another example, as shown in FIG. 5C, the multilobal fiber 500 may have a substantially elongated cross-section to allow for a greater number of lobes 505 and thus a greater number of channels 515 between adjacent lobes the number of lobes may vary and may be, for example, 3-30, 3-20 or 3-10. As also shown in FIG. 5D, the spacing between lobes in the same fiber and the size of the lobes may vary. the multilobal fiber may preferably include surface features that may further improve its liquid handling properties.A further aspect of the multilobal fiber 500 includes a plurality of lobes 505 and channels 525 formed between adjacent lobes that may retain liquid and a further improve the ability of the multilobal fiber to retain a liquid or a liquid in the invention

A fiber for sale.

In some embodiments, a substrate according to the present invention may be hollow. An exemplary hollow fiber 600 is shown in fig. 6, the fiber having an outer wall 602 and a hollow interior 604, the outer wall 602 preferably being thin relative to the overall diameter of the fiber (e.g., a wall thickness of about 1% to about 20%, about 2% to about 15%, or about 3% to about 10% of the fiber diameter). In some embodiments, the hollow fibers may also be segmented. Hollow fibers are particularly beneficial in that the individual fibers can be substantially flat in the dry state and can swell to contain liquid when absorbed by a substrate formed from the hollow fibers. One specific example of a hollow segmented fiber that is particularly useful in the present invention is the fiber sold under the trade name BRAMANTE by Kelheim fibers.

The substrate according to the present invention may be formed from a single layer of non-woven fibers. The layers of fibers may be formed by any suitable method, such as wet and dry methods. Preferably, the fibers used to form the substrate are staple fibers. If desired, a binder may be used, such as may be commonly used with cellulose acetate. A binder is understood to be a material that imparts a binding effect to the fibers used to form the reservoirs of the present invention. For example, the binder may be a material that partially dissolves the fibers, bonds the fibers to each other, or to other fibrous materials contained in the nonwoven reservoir. Exemplary binders that may be used include polyvinyl acetate (PVA) binder, starch, and triacetin. In some embodiments, the adhesion may be provided by different means, such as by needling or other mechanical means to entangle the fibers with one another (e.g., hydroentanglement). Thus, the substrate may be defined by the actual physical structure as a needled substrate, wherein the fibers are intertwined with one another in a manner that is not present prior to performing the needling step. As such, the term "needling" is understood to refer to the physical state of the substrate rather than the process. Likewise, the term "hydroentanglement" is understood to refer to the physical state of the substrate rather than the process. In other words, when hydroentangling is a possible modification process of a substrate, a hydroentangled substrate is a material which is defined, at least in part, by the entanglement of fibers which is not present before the hydroentangling step is performed.

In one or more embodiments, the substrate described herein may comprise a plurality of layers. For example, two or more layers having the same composition may be combined. Alternatively, two or more layers of different compositions may be combined.

The combination of layers may be configured to facilitate movement of the liquid in a first direction (e.g., on a side facing the first substrate layer) and to restrict movement of the liquid in a second direction (e.g., on a side facing the second substrate layer). As shown in fig. 7, the substrate 700 is formed from a first layer 760 and a second layer 770. The first substrate layer 760 is formed of fibers having high absorbency and configured to release absorbed liquid by wicking. The second substrate layer 770 is formed of fibers having low absorbency and configured to impede, reduce, or prevent the movement of liquid therein. As shown in fig. 7, the aerosol precursor composition absorbed in the first substrate layer 760 will be free to move and leave the first substrate layer (as indicated by the bold arrows) and the circulation of the aerosol precursor composition in the second substrate layer 770 (as indicated by the absence of the bold arrows) is substantially prevented. As such, other aerosol delivery device elements on the side of the substrate 700 comprising the first substrate layer 760 may freely receive the aerosol precursor composition absorbed in the first substrate layer such that the liquid is able to evaporate, and other aerosol delivery device elements on the side of the substrate comprising the second substrate layer 770 may remain substantially free of any contact with the aerosol precursor composition. As shown, the first substrate layer 760 is thicker than the second substrate layer 770; however, the two substrate layers may be substantially the same thickness, or the second substrate layer may be thicker than the first substrate layer. Additionally, in some embodiments, it may be useful to include a third substrate layer 780 between the first substrate layer 760 and the second substrate layer 770. The third substrate layer is optional and may comprise a material that aids in bonding the first substrate layer to the second substrate layer. Alternatively, the third substrate layer may be a mechanical isolation layer, such that the first substrate layer is not in direct contact with the second substrate layer, and liquid communication between the first and second substrate layers may be further reduced or prevented. As an alternative or in addition to the use of a third substrate layer, the bonding between the first and second substrate layers may be achieved by needling, hydroentanglement or the like. In addition, low-melting-point binder fibers may be included in one or both of the first substrate layer and the second substrate layer to independently bind fibers forming the independent substrate layers and/or to bind the first substrate layer and the second substrate layer. Any type of low melting binder fiber may be used for this purpose.

The second substrate layer may be formed of hydrophobic fibers. In some embodiments, hydrophobicity may be provided by additives that may be added to the fibers prior to fiber formation (i.e., in combination with the fiber-forming material), or to the fibers after fiber formation. For example, the fibers may be coated with one or more hydrophobic coatings that may be added to the fibers after formation and/or may be added to a substrate made from the fibers. In some embodiments, the hydrophobic fibers may be formed by adding a water repellent material during the fiber formation process. For example, long chain hydrocarbons may be covalently bound to the cellulosic material used to form the fibers prior to fiber formation. In this manner, the finally formed fibers may exhibit inherent hydrophobicity. An example of a hydrophobic fiber useful in the present invention is a fiber sold under the name OLEA by Kelheim fibers.

The second substrate layer may be substantially non-cellulosic if desired. For example, polymeric membranes that are substantially impermeable to aqueous liquids may be used.

An exemplary cartridge 804 for an aerosol delivery device 804 is shown in fig. 8, it being understood that the cartridge may be configured to connect with other bodies configured to provide power and control functions, such as the control body 102 shown in fig. 1. The cartridge 804 includes a housing 803 (or casing) and a reservoir 810, the reservoir 810 being formed from a substrate material as described herein, within the housing. Reservoir 810 is formed from a first substrate layer 810a and a second substrate layer 810 b. The first substrate layer 810a is formed of fibers configured to provide high absorbency and free release of liquid absorbed therein to a wicking material, such as a liquid transport element 840 having a heater 840 surrounding it. The second substrate layer 810b is formed of fibers configured to be substantially hydrophobic and therefore transport little or no liquid in the first substrate layer 810 a. An annular gap 881 exists between the reservoir 810 and the outer shell 803, but it is understood that the reservoir may be in direct contact with the inner surface of the outer shell. Thus, a dual layer substrate is beneficial in that the pre-aerosol bodily fluid stored in the first substrate layer 810a is easily wicked to the heater 840 through the liquid transport element 830; however, in the event that liquid can exit the cartridge and may leak from the cartridge housing 803, and/or in the event that liquid finds its way into the control body and may cause battery and/or controller failure, the flow of aerosol precursor to the annular gap 881 is substantially prevented.

In some embodiments, a substrate according to the present invention may be defined by its basis weight. Preferably, the substrates described herein may exhibit a greater load bearing capacity than other fibrous materials having the same basis weight. For example, the basis weight of a substrate according to the present invention may be from about 100 grams per square meter (GSM) to about 250GSM, from about 110GSM to about 230GSM, or from about 120GSM to about 220 GSM.

Percent load bearing capacity can be calculated from the initial dry weight of the substrate sample and the weight of the substrate sample when saturated with the test solution. Thus, the percent load capacity can be calculated according to the following equation.

In some embodiments, the support capacity of a substrate according to the present invention may be greater than or equal to about 1500%, greater than or equal to about 2000%, or greater than or equal to about 2500%, as calculated by the above equation. Specifically, the loading capacity of the substrates described herein may be from about 1500% to about 5000%, from about 1700% to about 4700%, from about 2000% to about 4500%, or from about 2500% to about 4000%, as calculated by the above equation.

Example 1 absorbency

In order to evaluate the absorbency of the substrate, a plurality of substrates in the form of a single-layer substrate or a multi-layer substrate were prepared. Three different types of fibers were used to form the samples. BRAMANTE hollow segmented fibers (3.3 dtex) x 40mm) having a substantially circular or elliptical cross-section (hereinafter "B");

trilobal fibers (3.3 dtex x30mm) with striations (hereinafter "G"); and OLEA hydrophobic fibers (1.7 dtex x30mm) having long chain hydrocarbons (hereinafter referred to as "O") covalently cross-linked to the fiber-forming material. All three fibers are formed from regenerated cellulose. The single-layer base material is formed by short fibers of three types of fibers, and each base material is only formed by one typeFibers-i.e., 100 weight percent B fibers, 100 weight percent G fibers, or 100 weight percent O fibers. Control and comparative samples were prepared using plain-woven cellulose acetate. All substrates were formed using a dry process. For all monolayer samples, 80 grams of fiber were weighed for each sample. The fibers were passed through the card three times to ensure acceptable opening and uniformity of the final network. For the two-layer sample, 40 grams of fiber was used for each layer to make the network. For uniformity and dispersion, the fibers were passed through the card three times again. The layers are then stacked on top of each other for needling or laminated with an adhesive web for glue bonding. For the three layer sample, 26.5 grams of each fiber was weighed and then the same procedure was performed as for the single and double layer samples. Needling is carried out on a felting Loom laboratory needle Loom (Felt Loom layneedler). Each sample was passed through a needle loom four times (twice per side). Both the needle loom speed and the number of punctures per inch (ppi) were set at 50%. Each needle used had six barbs. The "tacky" sample adheres to a lightweight polyethylene adhesive web (e.g., Bostik PO104 hot melt web adhesive). The samples were laminated with an adhesive web and hot pressed at 240 ° F for 30 minutes. Samples of the substrate were tested and the comparative subjects of the test were plain woven cellulose acetate substrate, needle punched plain woven cellulose acetate substrate, and organic cotton substrate. Samples of 15 inventive substrates according to the invention were evaluated and the composition of each substrate is shown in table 1 below, together with the composition of the control and comparative samples.

The e-liquid composition was applied to each test sample. The electronic cigarette liquid is formed by glycerin, propylene glycol, water and perfume. The e-liquid was slowly added to the test sample until the saturation point was reached and the sample had no more liquid to hold. The mass of liquid added to the samples was used to calculate the percent carrying capacity, and the resulting percent carrying capacity for each sample is shown in figure 9. As shown in the figure, all of the inventive sample substrates exhibited higher percent load bearing capacity than control cellulose acetate (CON1), needle-punched cellulose acetate (COMP1), and organic cotton (COMP 2).

The relative increase in carrying capacity compared to the cellulose acetate control sample was also calculated. The results are shown in FIG. 10. As shown in the figure, the sample substrates of the present invention showed a relative increase in loading capacity of up to 2.15 times compared to the cellulose acetate control. The relative loading capacity relative to the Cellulose Acetate (CA) control was calculated according to the following equation.

Example 2 Aerosol formation

The ability of the substrate to release the aerosol precursor composition for aerosol formation was evaluated by using each sample from example 1 in a test apparatus. Testing was performed using a cartridge having a similar structure to cartridge 104 shown in fig. 1. Each test sample was provided in a uniform scale and used as the reservoir 144 shown in fig. 1. The smoking simulation was performed using a commercially available smoking simulation device, i.e., a smoking machine. By suction for 3 seconds (55 cm)³Volume) and a pumping interval of 30 seconds. The mean value was taken as the midpoint of the aspiration group. The mass measurements were performed at 0 th puff, followed by 20 separate aspirates collected on a Cambridge filter pad (Cambridge filter pad) commonly used to collect Total Particulate Matter (TPM) in cigarette smoke for each reservoir, substrate material, respectively. The total mass produced was divided by 20 to give the mass per puff. For the purpose of the drawing, the average mass per puff at the midpoint of the puff group (i.e., the mass at the 10 th puff) is taken.

The test results are shown in figures 11 and 12, where aerosol generation for each sample is shown based on the TPM per puff on a test device comprising various substrates. To confirm whether the multilayer substrate is more conducive to liquid saturation of one side of the substrate relative to the other side of the substrate, a test was conducted on a multilayer substrate sample oriented in both directions. In the legend of fig. 11 and 12, the designation of fibers followed by the word "inward" indicates that the substrate layer is oriented inward toward the wick and heater. The number of each substrate in the legend is also related to the basis weight of that substrate. For multi-layer substrates, the presence of the word "tacky" in the legend indicates that the layers are adhered together. Needle punching was used in all other samples.

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. An aerosol delivery device comprising:

a housing;

a substrate formed at least in part from regenerated cellulose fibers;

an aerosol-forming liquid held by the substrate; and

a heater operatively arranged to vaporize the aerosol-forming liquid;

wherein the regenerated cellulose fibers comprise one or more of the following fibers: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive.

2. The aerosol delivery device of claim 1, wherein the regenerated cellulose fibers have a multi-lobal cross-section and comprise stripes extending longitudinally along the surface of one or more lobes of the fibers.

3. The aerosol delivery device of claim 1, wherein the substrate is a nonwoven.

4. The aerosol delivery device of claim 1, wherein the substrate comprises a plurality of layers.

5. The aerosol delivery device of claim 4, wherein the plurality of layers are needle punched.

6. The aerosol delivery device of claim 4, wherein the plurality of layers are bonded together.

7. The aerosol delivery device of claim 4, wherein the substrate comprises a first layer comprising one or both of regenerated cellulose fibers having a hollow, substantially cylindrical cross-section and regenerated cellulose fibers having a multi-lobal cross-section, and a second layer comprising regenerated cellulose fibers comprising a hydrophobic additive.

8. The aerosol delivery device of claim 4, wherein the first layer is configured to store and release the aerosol precursor composition and the second layer is hydrophobic.

9. The aerosol delivery device of claim 1, wherein the substrate forms at least a portion of a reservoir.

10. The aerosol delivery device of claim 9, further comprising a liquid transport element in fluid communication with the reservoir and in fluid communication with the heater.

11. The aerosol delivery device of claim 1, wherein the substrate forms at least a portion of a liquid transport element in fluid communication with the reservoir and in fluid communication with the heater.

12. The aerosol delivery device of claim 1, wherein the substrate is in direct contact with a heater.

13. The aerosol delivery device of claim 1, wherein the substrate has an aerosol precursor composition carrying capacity of at least 2000% relative to the initial dry weight of the substrate.

14. The aerosol delivery device of claim 1, wherein the substrate has a basis weight of about 100gsm to about 250 gsm.

15. The aerosol delivery device of claim 1, wherein the aerosol delivery device further comprises a power source and a controller.

16. A method of making an aerosol delivery device, the method comprising:

providing a housing;

disposing a substrate within the housing, at least a portion of the substrate being formed from regenerated cellulose fibers comprising one or more of the following: regenerated cellulose fibers having a hollow, substantially cylindrical cross-section; regenerated cellulose fibers having a multi-lobal cross-section; regenerated cellulose fibers comprising a hydrophobic additive; and

disposing the substrate in fluid communication with a heater within the housing;

wherein an aerosol-forming liquid is retained by the substrate before or after the substrate is placed within the housing.

17. The method of claim 16, further comprising combining the housing with a cuff.

18. The method of claim 16, further comprising combining the housing with a second housing comprising a battery and a controller.